Recycled corrugated child&#39;s chair

ABSTRACT

A furniture assembly and structuring systems comprising the insertion of tenons of multilayered corrugated Kraft into mortises in panels of corrugated Kraft in order to obtain furniture structures and other structures that are sturdy, as well as being light and self-supporting and optionally made from recyclable material. The tenons have a folding flap and tuck slot that form an interlocking connection. The invention also relates to a furniture assembly and structuring systems made from panels comprising layered corrugated Kraft comprising a dovetail and slot assembly. The applications are multiple, ranging from items of furniture such as chairs, tables, benches, shelves, items for loading products, display units, and packagings. The assembly systems are also designed to be set up in such a way that it is practical and easy for the user without needing to use tools. It enables and facilitates the transport of the structures prior to assembly in parts arranged in a compact manner, occupying a relatively small space.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the provisionalapplication No. 61/938,913 filed Feb. 12, 2014 (titled RECYCLEDCORRUGATED CHILD'S CHAIR, by Matthew Gerstle), which is incorporated byreference herein. Provisional application No. 61/938,913 is not admittedto be prior art with respect to the present invention by its mention inthe background or cross-reference section.

BACKGROUND OF THE INVENTION

This invention relates to furniture structures, for example a child'schair, consisting of substantially planar members which interlockwithout the use of tools or separate fasteners, and that are made frommulti-layered, optionally recycled, corrugated or honeycomb Kraft (forexample single face, single wall, double wall, triple wall), and thatcan be optionally recycled when no longer wanted by the consumer. Theinvention also relates to furniture structures or other structures thatcan pack flat during shipping, that are easy to assemble by the end-userwithout the use of tools or separate fasteners and that are made usingmulti-layer, optionally recycled, corrugated Kraft that is alsooptionally recyclable. This invention also relates to a mortise andtenon assembly as well as a dovetail and slot assembly.

There has been a need in the art for lightweight, easy to assembletemporary structures including furniture and children's furniture. Otherexamples of structures include chairs, stools, tables, benches, shelves,items for loading products, display units, and packaging. In some casesit is desired to be able to recycle the item after it is used.Corrugated Kraft (for example cardboard) is a lightweight material.Items made from corrugated Kraft require special designing to providerigid or strong structures.

Corrugated Kraft can be recycled, giving it a potentially sustainablecomplete lifecycle. The original Kraft can optionally be made fromrecycled material. The chair, for example, can be used for a period oftime and then it can be recycled.

Cardboard is one generic term that can be used in place of Kraft,corrugated Kraft, corrugated cardboard, or flute. The art containsexamples of cardboard structures with various assemblies and structuralattachments and the art also contains examples of child's chairs madefrom tool-less assembly.

Another term that can be used in place of “corrugated Kraft” is“corrugated board”. Other terms in the art for corrugated structuresinclude single face, single wall and double wall.

Some glues and coatings used on cardboard assemblies, for example glueused to combine several individual layers of corrugated Kraft to make amulti-ply sheet, are not compatible with recycling, in a process knownas re-pulping. There is an industry standard testing procedure todetermine if a glue or additive is compatible with re-pulping.

U.S. Pat. No. 4,556,253 (Geneve, Heiligenstein and Melamed) Teaches adisposable chair made from a single unitary die-cut and scored blanksheet of material.

Structures have been made from corrugated paperboard with certainstructural members. U.S. Pat. No. 4,266,670 (Grigsby, Banks and Grigsby,Jr.) Teaches a collapsible reinforced container using a structuralmember formed from a billet. It also teaches a manufacture built up ofcorrugated paperboard sheets.

Modular knockdown furniture has been made from a kit of inter-fittingparts. U.S. Pat. No. 5,407,250 (Prince, Phillips, Hodge and Kitchen)teaches quick to assemble modular chair with a compact packingarrangement.

U.S. Pat. No. 5,263,766 (McCullough) teaches a unit of child's furnituresuch as a chair or sofa that is constructed of intersecting panelsprovided with a unique interlocking joint which provides strength,rigidity and long life to such furniture. In one form, each panel ismade of a pair of triple wall corrugated cardboard sheets which areindividually slotted and channeled to provide different portions of itsjoint, and which thereafter have their sides cemented together to form adouble thickness corrugated panel. The furniture is preferably made soit can be transported and stored in flat, knockdown condition andassembled when needed.

US 2007/0102986 A1 (Buhrman) teaches a chair assembly kit comprising atleast two end pieces, at least two middle pieces including a firstmiddle piece as a chair back and a second middle piece as a chair seat,and at least four locking pieces. The middle pieces each include atleast two tabs, one tab each on two opposing sides and each tab defininga hole. The end pieces each include at least two slots configured toreceive the tabs on the middle pieces. The locking pieces each includeat least two posts each having a detent mechanism, the posts beingreceived in the holes in the middle pieces. The middle piecesselectively couple to the end pieces, and the locking pieces selectivelylock the middle pieces to the end pieces via the detent mechanisms, toform a chair.

U.S. Pat. No. 5,387,027 (Maloney) teaches a furniture structure forchairs, benches and the like consisting of substantially planar memberswhich interlock and reversibly unlock without the use of tools orseparate fasteners, comprises two sides, a seat member, a back and afront, the sides each having an upper edge, and the seat memberincluding a forward edge and a rear edge. An interlocking sector on eachof the sides interlocks with the seat member, the back and the frontwithout the need for tools or separate fasteners. The interlockingsector includes first and second members on each of the sides forfrictionally engaging the forward and rear edges of the seat member,respectively, in opposite directions. A third member on each of thesides frictionally engages the seat member in a direction substantiallyperpendicular to the opposite directions. Back locks on each of thesides interconnect the back to each of the sides, and include an upperback lock and a lower back lock, The lower back lock is separated fromthe upper back lock at least by a distance equal to the distance betweenthe upper edges of the sides when the structure is in a fully assembledcondition. A front lock on each of the sides interlocks the front toeach of the sides.

US 2012/0056463 A1 (Berent and Hulewat) teaches an article of furnitureand associated methods and kits comprising at least one first legsupport structure, at least one second leg support structure, the atleast one first leg support structure being inter-fitted with the atleast one second first leg support structure via an interference fit todefine a support assembly, a top that is supported by and attached tothe support assembly without the need for a mechanical fastener oradhesive; and means for creating a force state that attaches the top tothe support assembly without the need for a mechanical fastener oradhesive, and thereby stabilizes the article of furniture, wherein theforce state includes one or more forces applied to the at least onefirst leg support structure and the at least one second leg supportstructure, in addition to any frictional force from the interferencefit.

US 2009/0066140 A1 (Berent and Hulewat) teaches an article of furnitureand associated methods and kits comprising at least one first legsupport structure, at least one second leg support structure, the atleast one first leg support structure being inter-fitted with the atleast one second first leg support structure via an interference fit todefine a support assembly, a top that is supported by and attached tothe support assembly without the need for a mechanical fastener oradhesive; and means for creating a force state that attaches the top tothe support assembly without the need for a mechanical fastener oradhesive, and thereby stabilizes the article of furniture, wherein theforce state includes one or more forces applied to the at least onefirst leg support structure and the at least one second leg supportstructure, in addition to any frictional force from the interferencefit.

U.S. Pat. No. 7,219,962 B2 (Stone) teaches a furniture system comprisingmutually supporting components including a pair of identicallyconfigured side panels, a load supporting panels and a back panel. Theback panel engages the side panels and the load supporting panel toprovide rigidity to the furniture item. A locking member is providedthat holds the furniture item rigidly in an assembled condition.

U.S. Pat. No. 6,109,695 (Kahwaji) teaches a chair assembly havingdetachably interfitting parts. A right hand side support of the chairassembly includes slots extending from the exterior profile of the firstside support towards the center of the side support. A left hand sidesupport similar to the right hand side support is also provided. A seatpan having extensions is fitted into two complementary slots of theright and left side supports. A back support having extensions is alsofitted into two complementary slots of the right and left side supports.The seat pan and the back support may be independently adjusted so as topresent various sitting positions.

U.S. Pat. No. 8,112,868 B2 (Miller) teaches a method for manufacturing achair assembly with a customized backrest includes fabricating astandardized frame, preparing a contoured plywood blank for thebackrest, selecting a customized design for the backrest and thenconverting the design for the backrest into a readable format, loadingthe readable format for the backrest design into a customized cuttingapparatus, loading the blank into the cutting apparatus, cutting theblank in conformity with the selected backrest design, removing thecompleted blank from the cutting apparatus, mounting the backrest ontothe frame, and lastly, mounting a seat onto the frame.

One way to connect two cardboard members together is using a dovetailand slot. U.S. Pat. No. 5,836,254 (Johansson) teaches a pallet having aplurality of parallel base beams, and a deck joined to the plurality ofparallel base beams. The deck includes a web or sheet of material, whichis folded to form a deck surface with a plurality of parallel panelsadjoining each other, and a plurality of parallel projections on anunderside thereof. Each base beam extends upward to contact theunderside of the parallel panels, and includes at least onethrough-recess having a shape which corresponds to a cross-section of acorresponding one of the plurality of parallel projections. Thecorresponding parallel projection engages the recess thereby forming thepallet with a plurality of spaces to accommodate lifting forks betweenthe plurality of parallel base beams. Lower surfaces of the plurality ofparallel projections form lifting surfaces for the lifting forks.

All of these references contain at least one of the followingshortcomings: the item is not made from multi-layered corrugated Kraft,the item does not have a tool-less assembly, thus complicating theassembly process, the item does not have robust connections that form along-lasting tight connection, the item does not have the aestheticallypleasing look and feel of natural wood, the item is not made from allmaterials (coatings, inks, glues) that are compatible with municipalrecycling.

Recyclable manufactured items can be tested for water re-pulpability tocertify recyclability. A standard test method is TAPPI Method UM 213(2012) “Re-pulpability of splices/splicing tape”, and is incorporated byreference herein.

Thus, there is a significant need in the art for furniture structuresfor children that have at least one of the following traits: it is madefrom corrugated Kraft (lightweight, easy to ship), it has an easy,tool-less assembly, it is sturdy, it has the pleasing look and feel ofnatural wood, it can optionally be made from recycled material (andcompatible with re-pulping), it is free-standing and can be movedwithout having to disassemble it. There is also a need in the art forsturdy, tool-less connections for structures made using substantiallyplanar members made from layered corrugated Kraft.

BRIEF SUMMARY OF THE INVENTION

This invention relates a furniture assembly and structuring systemscomprising the insertion of tenons of multilayered, optionally recycled,corrugated Kraft into mortises of panels of multi-layer, optionallyrecycled, corrugated Kraft in order to obtain furniture structures andother structures that are sturdy, as well as being light andself-supporting (or free-standing) and made from recycled or recyclablematerial. The invention also relates to a furniture assembly andstructuring systems made from panels comprising layered corrugated Kraftcomprising the insertion of a dovetail into a slot. The applications aremultiple, ranging from items of furniture such as chairs, tables,benches, shelves, items for loading products, display units, andpackagings. The assembly system is also designed to be set up in such away that it is practical and easy for the user to assemble withoutneeding to use tools or interlocking glue. It enables and facilitatesthe transport of the structures in parts prior to assembly arranged in acompact manner, occupying a relatively small space. The invention alsorelates to a furniture assembly and structuring system that isfree-standing, meaning it can be picked up and moved without fallingapart or disassembling into the separate panels.

The invention solves the shortcomings of the prior art and provides auseful structure needed in the art.

An embodiment of this invention is a furniture structure for chairsconsisting of substantially planar members which interlock without theuse of tools, interlocking glue or separate fasteners, comprising: twoside members, a lateral support member, a seat member, a back member,wherein all of the members comprise at least two glued corrugated Kraftlayers, and optionally at least three glued corrugated Kraft layers; theside members each having a floor contacting bottom edge, a front edge, aback edge, a substantially horizontal upper seat contact edge and asubstantially vertical back support extension, a forward facing backmember contacting edge, the side members each having a slot to accept adovetail, the slot is positioned facing the inside of the chair andsubstantially located midway between the front and back of the chair,the side members each having at least one tenon extending from the upperseat contact edge and at least one tenon extending from the forwardfacing back member contacting edge, both tenons also containing afoldable flap extending beyond the length of the tenon, and the sidemembers comprise at least one tuck slot in proximity to each tenon, thetuck slots positioned on the outside of the side members, facing awayfrom the chair center; the seat member including a forward edge, a rearedge, two side edges distal to each other, two mortises located one eachin proximity to each of the side edges, wherein each mortise forms ahole that penetrates the entire depth of the seat member, forming apass-through opening that accepts the tenon on the upper seat contactingedge of the side members; the back member including a bottom edge, a topedge, two side edges distal to each other, and two mortises located oneeach in proximity to each of the side edges, wherein each mortisepenetrates the entire depth of the back member, forming a pass-throughopening that accepts the tenon on the forward facing back membercontacting edge of the back support extension of the side members; thelateral support member including a bottom edge, a top edge, two sideedges distal to each other, two substantially rectangular dovetails, oneon each side edge of the lateral support; on each of the side members, ameans for interlocking the side member with the lateral support member,each means for interlocking comprising a frictionally engaged dovetailand slot connection formed by slidibly inserting one of the dovetails ofthe lateral support member into the corresponding slot of the sidemembers forming a substantially tight connection, and wherein thelateral support member is substantially perpendicular to each of theside members; on each of the side members, a means for interlocking theside member with the seat member, the means for interlocking comprisinga mortise and tenon connection, wherein the tenon on each of the sidemembers comprises an extended foldable flap, the tenon is slidiblyinserted into the mortise of the seat member forming a substantiallytight connection, and the connection is locked together by folding theextended flap around the outside of the seat member and the end of theflap is inserted into the tuck slot on the side member; on each of theside members, a means for interlocking with the back member, the meansfor interlocking means comprising a mortise and tenon connection,wherein the tenon on each of the side members comprises an extendedfoldable flap, the tenon is slidibly inserted into the mortise of theback member forming a substantially tight connection, and the connectionis locked together by folding the extended flap around the outside ofthe back member and the end of the flap is inserted into the tuck sloton the side member.

Another embodiment is a tab on the end of the flap that is inserted intothe tuck slot.

Another embodiment is a veneer layer glued to at least one surface oredge of at least one of the members.

Another embodiment is a wood veneer layer.

Another embodiment is at least one member comprising more than threecorrugated Kraft layers.

Another embodiment is wherein the Kraft is selected from the groupconsisting of Kraft paper, fiberboard, chipboard, paperboard and paperhoneycomb.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C fluteD flute, G flute, N flute, double wall AB, double wall BC, double wallBB, double wall AC, E flute, double wall EE, F flute, double wall EB,double wall CC, triple wall EBE, triple wall ABB, triple wall CBC flute,and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C flute,double wall AB, double wall BC, double wall BB, double wall AC, E flute,double wall EE, F flute, double wall EB, double wall CC, triple wallEBE, triple wall ABB, and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of C flute, double wall BCand double wall EE.

In another embodiment the corrugated Kraft comprises double wall BC andB flute, preferably three layers of double wall BC and one layer of Bflute, optionally four layers of double wall BC.

In an embodiment the corrugated Kraft comprises optionally two layers ofC flute, three or more layers of C flute, two layers of B flute or threeor more layers of B flute.

Another embodiment is wherein the seat member comprises an outer planarsurface, a recess along the outer planar surface and a recess along thefold-over edge, wherein the flap is folded into the two recesses andtucked into the tuck slot, and wherein the folded flap occupies a spacein each recess and forms a substantially flush surface with the outerplanar surface and fold-over edge of the seat member.

Another embodiment is wherein the back member comprises an outer planarsurface, a recess along the outer planar surface and a recess along thefold-over edge, wherein the flap is folded into the two recesses andtucked into the tuck slot, and wherein the folded flap occupies a spacein each recess and forms a substantially flush surface with the outerplanar surface and fold-over edge of the seat member.

Another embodiment is further comprises a free-standing assembly.

An embodiment of this invention is a mortise and tenon assembly for twosubstantially planar members, the assembly comprising: a first memberand a second member that each comprise at least two glued corrugatedKraft layers; the first member has a first contacting edge, and a firstplanar surface, the first contacting edge and first planar surfaceforming a substantially right-angled corner, and the second member hasan inner planar surface, an outer planar surface and a fold-over edge,the inner planar surface and the outer planar surface are substantiallyparallel to each other and connected by the fold-over edge, each planarsurface forming a substantially right-angled edge with the fold-overedge; the first member has a tenon-flap assembly that extends from thefirst contacting edge, the tenon-flap assembly is comprised of a tenonand a flap, wherein the tenon comprises at least one corrugated Kraftlayer, and wherein the flap comprises at least one corrugated Kraftlayer, the tenon and flap assembly comprises a multi-layer corrugatedKraft assembly comprising both the tenon and flap that in combinationhave at least two corrugated Kraft layers in total, wherein the flapextends a longer length from the first contacting edge than the lengththat the tenon extends from the first contacting edge, the first memberfurther comprises at least one tuck slot in proximity to the tenon,wherein the tuck slot is located on the first planar surface; the secondmember has a mortise wherein the mortise penetrates the entire depth ofthe second member, forming a pass-through opening that accepts thetenon-flap assembly on the first member; a means for interlocking thefirst member and the second member, the mean for interlocking comprisinga mortise and tenon connection, wherein the tenon on the first member isinserted by sliding into the mortise of the second member forming asubstantially tight connection, and the connection is locked together byfolding the extended flap around the fold-over edge of the second memberand the flap is inserted into the tuck slot on the first member.

Another embodiment is wherein the first member and the second memberseach comprise at least three glued corrugated Kraft layers.

Another embodiment is wherein the first and second members aresubstantially perpendicular to each other.

Another embodiment is wherein the terminal end of the tenon, the end ofthe tenon that is furthest from the first contacting edge, extends intothe mortise of the second member so that the terminal end of the tenonis substantially flush with the outer surface of the second member.

Another embodiment is wherein the tenon-flap assembly on the firstmember comprises a Kraft layer of the tenon-flap assembly that isfurthest away from the fold-over outside edge of the second member,wherein the flap is folded over the other layers of the tenon-flapassembly, covering the exposed end of the tenon from view, and the flapis further folded around the fold-over edge of the second member andinserted into the tuck slot of the first member.

Another embodiment is wherein the flutes of the corrugated Kraft layersin the tenon and in the flap are aligned substantially parallel to eachother.

Another embodiment is wherein the flutes of the corrugated Kraft layersin the flap are substantially perpendicular to the corrugated Kraftlayers in the tenon.

Another embodiment is wherein the second member comprises a recess alongthe outer planar surface and a recess along the fold-over edge, whereinthe flap is folded into the two recesses and tucked into the tuck slot,and wherein the folded flap occupies a space in each recess and forms asubstantially flush surface with the outer planar surface and fold-overedge of the second planar member.

Another embodiment further comprises a tab on the end of the flap thatis inserted into the tuck slot.

Another embodiment is further comprises a veneer layer glued to at leastone surface or edge of at least one of the members.

Another embodiment is wherein the veneer layer is wood.

Another embodiment comprises at least one member comprising more thanthree corrugated Kraft layers.

Another embodiment is wherein the Kraft is selected from the groupconsisting of Kraft paper, fiberboard, chipboard, paperboard and paperhoney comb.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C fluteD flute, G flute, N flute, double wall AB, double wall BC, double wallBB, double wall AC, E flute, double wall EE, F flute, double wall EB,double wall CC, triple wall EBE, triple wall ABB, triple wall CBC flute,and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C flute,double wall AB, double wall BC, double wall BB, double wall AC, E flute,double wall EE, F flute, double wall EB, double wall CC, triple wallEBE, triple wall ABB, and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of C flute, double wall BCand double wall EE.

Another embodiment is wherein the tenon has at least two corrugatedKraft layers, the tenon and flap assembly comprises a multi-layercorrugated Kraft assembly comprising both the tenon and flap that incombination have at least three corrugated Kraft layers.

An embodiment of this invention is a dovetail and slot assembly for twosubstantially planar members, the assembly comprising: a first memberand a second member that each comprise at least two corrugated Kraftlayers; the first member has a first contacting edge, and a first planarsurface, the first contacting edge and first planar surface forming asubstantially right-angled corner, and the second member has a secondcontacting edge and a substantially rectangular dovetail cantileveredfrom of the second contacting edge; the first planar surface having aslot to accept a dovetail, the slot optionally having a roundedentrance; the dovetail having a rectangular block and a fin, wherein therectangular block is wider than the fin and the block is attached to thefirst member by the fin; wherein the fin comprises at least onecontinuous corrugated Kraft layer that also makes up at least a portionof the first member, and wherein the block comprises a center portioncomprising a continuous corrugated Kraft layer that extends through thefin and into the first member, and the block comprises at least two moreglued layers of corrugated Kraft than the number of layers of corrugatedKraft in the fin; a means for interlocking the first and second members,the means for interlocking comprising a frictionally engaged dovetailand slot connection formed by slidibly inserting the block of thedovetail into the slot of the first member forming a substantially tightconnection, and wherein the first and second members are substantiallyperpendicular to each other.

Another embodiment is wherein the fin comprises at least three gluedcorrugated Kraft layers.

Another embodiment is wherein block comprises at least three layers ofcorrugated Kraft glued on each side of the fin, such that the blockcontains at least six more Kraft layers than the fin.

Another embodiment is wherein the flutes of the corrugate in the fin areperpendicular to flutes of at least one of the other layers in theblock.

Another embodiment is wherein the flutes of the corrugate in the fin arealigned substantially parallel to a longitudinal axis of the dovetail.

Another embodiment comprises at least one member comprising more thanthree corrugated Kraft layers.

Another embodiment is wherein the Kraft is selected from the groupconsisting of Kraft paper, fiberboard, chipboard, paperboard and paperhoney comb.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C fluteD flute, G flute, N flute, double wall AB, double wall BC, double wallBB, double wall AC, E flute, double wall EE, F flute, double wall EB,double wall CC, triple wall EBE, triple wall ABB, triple wall CBC flute,and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of A flute, B flute, C flute,double wall AB, double wall BC, double wall BB, double wall AC, E flute,double wall EE, F flute, double wall EB, double wall CC, triple wallEBE, triple wall ABB, and triple wall ACA flute.

Another embodiment is wherein the corrugated Kraft comprises a flutethat is selected from the group consisting of C flute, double wall BCand double wall EE.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 Child's chair assembly.

FIG. 2A Child's chair assembly side view.

FIG. 2B Child's chair assembly front view

FIG. 2C Child's chair assembly exploded view.

FIG. 3 Single wall corrugated Kraft layer.

FIG. 4 Triple wall corrugated Kraft layer.

FIG. 5 Dovetail and slot interlocking means.

FIG. 6 Mortise and tenon interlocking means.

FIG. 7 Wood veneer on Kraft multi-layer.

FIG. 8A Parts of a mortise and tenon assembly.

FIG. 8B Parts of a mortise and tenon assembly alternate view.

FIG. 9A Mortise and tenon assembly with recess.

FIG. 9B Mortise and tenon assembly without recess.

FIG. 10 Flutes in the tenon and flap assembly.

FIG. 11 Recess near mortise in planar member.

FIG. 12 Fold over flap flush with outer surface, occupying recess.

FIG. 13 Dovetail and slot.

FIG. 14 Slot with rounded entrance.

FIG. 15 Flutes in dovetail parts.

FIG. 16 Standard flute dimensions.

FIG. 17 Two layers of corrugated Kraft made from one flute layer and onehoneycomb layer.

FIG. 18 Example of a first member containing a honeycomb Kraft layer.

FIG. 19 Dovetail block made from folding over a scored section of thefin layer.

DETAILED DESCRIPTION OF THE INVENTION

The summary of the invention above and in the Detailed Description ofthe Invention, and the claims below, and in the accompanying drawings,reference is made to particular features of the invention. It is to beunderstood that the disclosure of the invention in this specificationincludes all possible combinations of such particular features. Forexample, where a particular feature is disclosed in the context of aparticular aspect or embodiment of the invention, or a particular claim,that feature can also be used, to the extent possible, in combinationwith and/or in the context of other particular aspects and embodimentsof the invention, and in the invention generally.

The term “comprises” and grammatical equivalents thereof are used hereinto mean that other components, ingredients, steps, etc. are optionallypresent. For example, and article “comprising” (or “which comprises”)component A, B, and C can consist of (i.e. contain only) components A,B, and C, or can contain not only components A, B, and C but also one ormore other components.

The term “at least” followed by a number is used herein to denote thestart of a range beginning with that number (which may be a range havingan upper limit or no upper limit, depending on the variable beingdefined). For example, “at least 1” means 1 or more than 1. The term “atmost” followed by a number is used herein to denote the end of a rangeending with that number (which may be a range having 1 or 0 as its lowerlimit, or a range having no lower limit, depending on the variable beingdefined). For example, “at most 4” means 4 or less than 4, and “at most40%” means 40% or less than 40%. When, in this specification, a range isgiven as “(a first number) to (a second number)” or “(a first number)−(asecond number)”, this means a range whose lower limit is the firstnumber and whose upper limit is the second number. For example 25 to 100mm means a range whose lower limit is 25 mm, and whose upper limit is100 mm.

One embodiment of the present invention comprises a child's chairassembly 10 that is made from substantially planar members thatinterlock without the use of tools, interlocking glue, or separatefasteners. The chair is assembled from a kit of parts that comprises twoside members 20, a seat member 40, a lateral support member 50 and aback member 60. Kraft is a paper fiber-based material know to a PersonHaving Ordinary Skill in the Art. Corrugated Kraft layers contain flutes14 aligned in a direction, the direction of the flutes can be the sameor different for each layer in an assembly of Kraft layers. Common flutetypes include A flute, B flute, C flute, double wall BC, E flute, doublewall EE, F flute, double wall EB, double wall CC, triple wall CBC flute,and triple wall ACA flute. It would be apparent to a Person HavingOrdinary Skill in the Art that other similar structures could besubstituted. One embodiment of the present invention is planar membersmade from glued corrugated Kraft layers, and a more preferred embodimentis a planar member made from a minimum of two glued Kraft layers.Another embodiment is a planar member made from a minimum of three gluedKraft layers.

The side members 20 comprise a floor contacting edge 21, a front edge22, a back edge 23, a substantially horizontal upper seat contact edge24, a substantially vertical back support extension 25, a forward facingback member contacting edge 26, a tuck slot 27, a tenon extending fromthe seat member contact edge 28, a tenon extending from the forwardfacing back member contacting edge 29, and foldable flaps 30.

The seat member 40 comprises a forward edge 41, a rear edge 42, sideedges 43, and at least two mortises 44. In a preferred embodiment theseat member has two mortises.

The back member 60 comprises a bottom edge 61, a top edge 62, two sideedges 63 distal to each other, a mortise 64 (located one each inproximity to each of the side edges).

The lateral support comprises a bottom edge 51, a top edge 52, two sideedges 53 distal to each other, and two substantially rectangulardovetails 54, one on each side of the lateral support.

The chair comprises a dovetail and slot interlocking means (a “meansfor” interlocking) 80 for connecting the side members to the lateralsupport. The chair also comprises mortise and tenon means (a “means for”interlocking) 90 for connecting the seat member and back member to theside members. The tenons comprise an extended folding flap 91. Thefolding flap may optionally have a tab 92 on the end of the flap.

The present invention provides a child's chair with the look and feel ofreal wood. Real wood is aesthetically pleasing, both visually and to thetouch. One embodiment of the present invention is a wood veneer 13 gluedat least to one of the outer layers of the planar members used to makethe chair.

Another embodiment of this invention is a mortise and tenon assemblymade from at least two substantially planar members, the members eachmade from a minimum of two corrugated Kraft layers, more preferably aminimum of three corrugated Kraft layers. The mortise and tenon assemblyprovides for the first time a tight-fitting and interlocking connectionwith a fold over flap and tuck slot. The assembled connection isfunctional and has a pleasing appearance because the interior flutestructure of the corrugate used to make the tenon is covered by thesmooth surface of the fold over flap.

The applications of the disclosed mortise and tenon are multiple,ranging from items of furniture such as chairs, tables, shelves, stools,items for loading products, display units, and packagings. The assemblysystem is also designed to be set up in such a way that it is practicaland easy for the user, without needing to use tools. It enables andfacilitates the transport of the structures in parts prior to assemblyarranged in a compact manner, occupying a relatively small space.

The mortise and tenon assembly 100 comprises a first member 110 with afirst contacting edge 111 and a first planar surface 112, a tenon-flapassembly 113 on the first contacting edge, wherein the tenon-flapassembly comprises a tenon 114 and a flap 115. The first member 110 alsocomprises a tuck slot 116 on the first planar surface in proximity tothe tenon.

The second member 120 comprises an inner planar surface 122, an outerplanar surface 123, a fold-over edge 124 and a mortise 125 in proximityto the fold-over edge.

The mortise and tenon assembly comprises an interlocking means (a “meansfor” interlocking) 130 where the tenon is slidibly inserted into themortise forming a substantially tight connection, and further thefold-over flap is folded around the fold-over edge and inserted into thetuck slot. In one embodiment the end of the tenon and the outer planarsurface of the second member form a substantially flush surface 140. Inthis embodiment the fold-over flap is not flush with the second memberouter planar surface. In another embodiment the fold-over flap ispositioned 141 furthest from the fold-over edge so that once folded itcovers the other layers of the tenon. The flutes of the tenon 142 andthe flutes of the flap 143 are aligned independent from each other. Inone embodiment The flutes of the tenon 142 and the flutes of the flap143 are aligned parallel 144 to each other. In a more preferredembodiment The flutes of the tenon 142 and the flutes of the flap 143are aligned perpendicular 145 to each other. This perpendicularalignment is best for providing a stiff tenon and a fold-over flap thateasily and uniformly folds at the proper location to form a tightconnection. The flap is preferably folded with the flutes perpendicularto the fold crease.

In one embodiment the second planar member comprises a recess 146 toaccept the fold-over flap. When the flap is folded and occupies therecess, the flap forms a substantially flush surface 147 with the outerplanar surface 123. In another embodiment the fold-over flap comprises atab 148 on the end to facilitate insertion into the tuck slot, andforming a tight connection.

Another embodiment of this invention is a dovetail and slot assemblymade from at least two substantially planar members, the members eachmade from a minimum of two corrugated Kraft layers, and more preferablya minimum of three corrugated Kraft layers. The dovetail and slotassembly provides a sturdy and tight-fitting interlocking connection.

The applications of the disclosed dovetail and slot are multiple, alsoranging from items of furniture such as chairs, benches, tables,shelves, stools, items for loading products, display units, andpackagings. The assembly system is also designed to be set up in such away that it is practical and easy for the user, without needing to usetools. It enables and facilitates the transport of the structures inparts prior to assembly arranged in a compact manner, occupying arelatively small space.

The dovetail and slot assembly 200 comprises a first member 210 with afirst contacting edge 211, a first planar surface 212, a slot 213, andoptionally, a rounded entrance 214. The second member 220 comprises asecond contacting edge, a dovetail, wherein the dovetail comprises arectangular block 223 and a fin 224.

The dovetail and slot assembly comprises an interlocking means (a “meansfor” interlocking) 230 where the dovetail is slidibly inserted into theslot forming a substantially tight connection. The flutes in the fin 240are preferably aligned parallel to the longitudinal axis of the dovetail243. This alignment provides a rigid fin in the assembly. The flutes inthe block 241 are preferably aligned perpendicular 242 to the flutes inthe fin. This alignment provides torsional and flexural rigidity to theassembly. The flutes in the block may optionally be aligned parallel 244to the longitudinal axis of the dovetail and also to the flutes in thefin.

Kraft paper or Kraft (kraft) is paper or paperboard (also calledcardboard) produced from chemical pulp produced in the Kraft process.Pulp produced by the Kraft process is stronger than that made by otherpulping processes; acidic sulfite processes degrade cellulose more,leading to weaker fibers, and mechanical pulping processes leave most ofthe lignin with the fibers, whereas Kraft pulping removes most of thelignin present originally in the wood. Low lignin is important to theresulting strength of the paper, as the hydrophobic nature of lignininterferes with the formation of the hydrogen bonds between cellulose(and hemicellulose) in the fibers.

Kraft pulp is darker than other wood pulps, but it can be bleached tomake very white pulp. Fully bleached Kraft pulp is used to make highquality paper where strength, whiteness and resistance to yellowing areimportant.

The term “fiberboard” means a type of engineered wood product that ismade out of wood fibers. Types of fiberboard (in order of increasingdensity) include particle board, medium-density fiberboard, andhardboard. Fiberboard is sometimes used as a synonym for particle board,but particle board usually refers to low-density fiberboard. Fiberboard,particularly medium-density fiberboard (MDF), is heavily used in thefurniture industry. For pieces that will be visible, a veneer of wood isoften glued onto fiberboard to give it the appearance of conventionalwood.

The term “Chipboard” means a type of paperboard generally made fromreclaimed paper stock.

The term “paperboard” means a thick paper-based material with athickness at least 0.25 mm. Paperboard can be single or multi-ply.Paperboard can be easily cut and formed, is lightweight, and because itis strong, is used in packaging.

The term “cardboard” is a general term used to refer to any heavy paperpulp based board.

The term “free-standing” as in the usage “a free-standing structure” oras in the usage “a free-standing assembly” means a structure or assemblythat once assembled it can be picked up, moved, rotated or otherwisetranslated from one orientation to another without causing any of thepanels, or parts, to disassemble.

Honeycomb is another type of structured Kraft that is understood to aPerson Having Ordinary Skill in The Art. Unlike corrugate Kraft, withflute edges aligning in contact with the external Kraft sheets, thehoneycomb structure is positioned perpendicular to the outer Kraftsheets.

The term “flute” is understood to a Person Having Ordinary Skill in theArt as a rounded or pleated structure used to make corrugated Kraft.

The term “interlocking glue” means a glue or adhesive material that isapplied and used during assembly of the interlocking panels. This termhas been defined to avoid confusing “interlocking glue” with the “glue”that is used to bond individual corrugated Kraft layers in theproduction of the substantially planar panels. At the time of assembly,the panels would have been previously manufactured using a “glue” tomake multi-ply corrugated Kraft. However, the person who will assemblethe furniture structure or other assembly will not require any“interlocking glue” to assemble the structure.

Although the present invention has been described in considerable detailwith reference to certain preferred version thereof, other versions arepossible. For example children's furniture, adult furniture, school orinstitutional furniture, corporate furniture, toys, play houses, stagesets, exhibit or trade show booths, temporary spaces, shelving, storage,containers, organization bins, temporary housing, decorative boxes, dollfurniture, building blocks, office furniture, entertainment furniture,tables, desks, bookshelves, beds, headboards, side tables, night stands,coffee tables, TV stands, drafting tables, dining room chairs and table,dressers, wardrobes, ottoman, storage benches, toy boxes, bunk beds,file cabinet. Therefore, the spirit and scope of the appended claimsshould not be limited to the description of the preferred versionscontained herein.

The reader's attention is directed to all references which are filedconcurrently with this specification and which are incorporated hereinby reference.

All the features in this specification (including any accompanyingclaims, abstract, and drawings) may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed in one example only of a generic series of equivalent ofsimilar features.

Any element in a claim that does not explicitly state “means for”performing a specific function, or “step for” performing a specificfunction, is not to be interpreted as a “means” or “step” clause asspecified in 35 U.S.C. §112, ¶6.

What is claimed is:
 1. A furniture structure for a chair consisting ofsubstantially planar members which interlock without use of tools,interlocking glue or separate fasteners, comprising: two side members, alateral support member, a seat member, a back member, wherein all of themembers comprise at least two glued layers selected from corrugatedKraft layers and honeycomb Kraft layers; the side members each having afloor contacting bottom edge, a front edge, a back edge, a substantiallyhorizontal upper seat contacting edge and a substantially vertical backsupport extension, a forward facing back member contacting edge, theside members each having a slot to accept a dovetail, the slot ispositioned facing inside of the chair and substantially located midwaybetween the front and back of the chair, the side members each having atleast one tenon extending from the upper seat contacting edge and atleast one tenon extending from the forward facing back member contactingedge, both tenons also containing a foldable flap, and the side memberscomprise at least one tuck slot in proximity to each tenon; the seatmember including a forward edge, a rear edge, two side edges distal toeach other, first two mortises located one each in proximity to each ofthe side edges, wherein each mortise forms a hole that penetrates theseat member, forming a pass-through opening that accepts the tenon onthe upper seat contacting edge of the side members; the back memberincluding a bottom edge, a top edge, two side edges distal to eachother, and second two mortises located one each in proximity to each ofthe side edges, wherein each mortise penetrates the back member, forminga pass-through opening that accepts the tenon on the forward facing backmember contacting edge of the back support extension of the sidemembers; the lateral support member including a bottom edge, a top edge,two side edges distal to each other, two substantially rectangulardovetails, one on each side edge of the lateral support; on each of theside members, a first means for interlocking the side member with thelateral support member, each means for interlocking comprising africtionally engaged dovetail and slot connection formed by slidiblyinserting one of the dovetails of the lateral support member into acorresponding slot of the side members forming a substantially tightconnection, and wherein the lateral support member is substantiallyperpendicular to each of the side members; on each of the side members,a second means for interlocking the side member with the seat member,the means for interlocking comprising a first mortise and tenonconnection, wherein the tenon on each of the side members comprises afirst extended foldable flap, the tenon is slidibly inserted into themortise of the seat member forming a substantially tight connection, andthe connection is locked together by folding the extended flap aroundthe outside of the seat member and the flap is inserted into the tuckslot on the side member; and on each of the side members, a third meansfor interlocking with the back member, the means for interlockingcomprising a second mortise and tenon connection, wherein the tenon oneach of the side members comprises a second extended foldable flap, thetenon is slidibly inserted into the mortise of the back member forming asubstantially tight connection, and the connection is locked together byfolding the extended flap around the outside of the back member and theflap is inserted into the tuck slot on the side member.
 2. The chair ofclaim 1, further comprising a tab on the flap that is inserted into thetuck slot.
 3. The chair of claim 1, further comprising a veneer layerglued to at least one surface or edge of at least one of the members. 4.The chair of claim 3, wherein the veneer layer is wood.
 5. The chair ofclaim 1, wherein the Kraft is selected from the group consisting ofKraft paper, fiberboard, chipboard, and paperboard.
 6. The chair ofclaim 1, wherein the corrugated Kraft comprises a flute that is selectedfrom the group consisting of A flute, B flute, C flute D flute, G flute,N flute, double wall AB, double wall BC, double wall BB, double wall AC,E flute, double wall EE, F flute, double wall EB, double wall CC, triplewall EBE, triple wall ABB, triple wall CBC flute, and triple wall ACAflute.
 7. The chair of claim 1, wherein the seat member comprises anouter planar surface, a recess along the outer planar surface and arecess along a fold-over edge, wherein the flap is folded into the tworecesses and tucked into the tuck slot, and wherein the folded flapoccupies a space in each recess and forms a substantially flush surfacewith the outer planar surface and the fold-over edge of the seat member.8. The chair of claim 1, wherein the back member comprises an outerplanar surface, a recess along the outer planar surface and a recessalong a fold-over edge, wherein the flap is folded into the two recessesand tucked into the tuck slot, and wherein the folded flap occupies aspace in each recess and forms a substantially flush surface with theouter planar surface and fold-over edge of the seat member.